Catalytic reaction apparatus



g- 1950 L. w. T. CUMMINGS 2,517,525

CATALYTIC REACTION APPARATUS Filed Oct. 13, 1947 I3 Sheets-Sheet 1 Fig.1

IN VEN TOR.

LELAND WI CUMMINGS BY 1950 L. w. T. CUMMINGS 2,517,525

CATALYTIC REACTION APPARATUS Filed Oct. 15, 1947 3 Sheets-Sheet 2 IN VEN TOR.

, LELAND WI. CUMMINGS M (Ma/w ATTORNEYSL Aug- 1950 L. w. T. CUMMINGS 2,517,525

CATALYTIC REACTION APPARATUS- Filed Oct. 15, 1947 3 Sheets-Sheet 3 I. I MN m...

INVENTOR.

BY LELAND w.1: cummss flm W 4W ATTORNEYS Patented Aug. 1, 1950 UNITED STATES PATENT OFFICE CATALYTIC REACTION APPARATUS Leland W. T. Cummings, Wyncote, Pa., assignor to Sun Oil Company, Philadelphia, Pa., acorporation of New Jersey Application October 13, 1947, Serial No. 779,559

16 Claims. 1 This invention relates to improved apparatus for conducting catalytic reactions and more particularly to apparatus for carrying out catalytic processes involving alternate endothermic and exothermic reactions. A typica1 process of this type is the catalytic conversion of hydrocarbons in a cyclic operation, wherein hydrocarbons are caused to react endothermically in the presence of a catalytic contact mass, causing deposition of carbonaceous deposits on the mass which reduce the catalytic activity, and the catalyst is then reactivated by burning off the carbonaceous material. The catalytic cracking of higher boiling hydrocarbons to lower boiling hydrocarbons is a specific example of this type of process. Other examples are reforming, dehydrogenation and the like. a More specifically, the present invention is concerned with an improved catalytic reactor for use in a stationary bed type of operatiomwherein the catalyst is employed in the form of a plurality of stationary beds within the reactor and. is regenerated periodically in situ by passing hot oxygen-containing gases through the several beds. The reactor is especially adapted for use in that type of catalytic conversion generally referred to in the art as adiabatic operation. By this is meant that both the endothermic and Figure l; and

can best be understood by reference to the ac- Figure 3 is an clevational view, partly in section, of a modified form ofreactor having external means for introducing additional reactants.

Referring to the drawings, Figures 1 and 2 a show one form of the reaction apparatus in which exothermic reactions are carried out without the a use of a circulating convective fluid for supplying heat to, or removing heat from, the reaction zone by indirect heat transfer. In other words in such adiabatic, operation the heat required for,

the endothermic reaction is supplied either as sensible heat of the reactants enterin the reaction zone or as heat stored in the contact mass during the previous regeneration period, while the heat evolved during the exothermic reaction either is stored in the contact mass for use in the subsequent on-stream period or else is removed from the reaction zone in the form of sensible drocarbon charge material introduced between the several beds of catalytic contact mass.

,The features and advantages of the invention the body of the reactor comprises a vertically cylindrical outer shell l0 having convex top and bottom end portions H and I2. An inlet connection or nozzle 13 is provided at the top for introducing vaporous reactants centrally within the reactor and an outlet connection I4 is provided at the bottom. Disposed concentrically within the reactor are a plurality of annular shaped trays which are each adapted to retain a bed of granular contact material. While for purpose of illustration four such trays or beds are shown, being designated as I5, [6, l1 and I8 from the innermost to the outermost bed respectively, it will be understood that any suitable or desired numbermay be provided. The trays are spaced apart radially thus providing an annular space between each pair of the same, and the outer tray 18 has an outer diameter less than the inner diameter of shell l0 so as to provide an outermost annular space l9 between tray I8 and the shell.

Each tray comprises outer and inner vertical,

walls which are continually perforated to permit flow of fluid therethrough. The inner perforate walls of trays l5, I6, I! and I8 are des-- ignated respectivelyas 20, 2|, 22 and 23, while the outer perforate walls are designated respectively as 24, 25, 2B and 21. Each tray has an imperforate circular top member covering the tray, these bein illustrated in the drawings as 28, 29, 30 and 3| from the innermost to the outermost tray, respectively. 'Iop member 3| on the outermost tray extends radially outward to outer shell It! so as to close 01? the outermost annular space l9 at its top as shown in Figure 1, so that reaction products issuing from bed l8 into annular space l9 will flow downwardly and out of the reactor through nozzle I4. An imperforate circular bottom member or plate 32 extending radially to the outer perforate wall 21 1 3 of the outermost tray may be provided to function as the bottom portion for each of the trays. Plate 32 also serves to close off the bottom of each of the annular spaces between trays as well as the bottom of the central space 33 within the innermost tray so as to cause the reactants to flow through the reactor in the desired manner as hereinafter described. Plate 32 may rest upon a plurality of beams 34 which extend transversely across the reactor and which may be supported therein by means of support lugs 35 secured to outer shell it in any suitable manner. Within each annular space between trays, there is provided a circular bafiie which extends from the bottom plate 32 to at least the top of the trays and preferably substantially above the trays.

These baffies, designated in Figures 1 and Z'as 36, v

3'! and 38, respectively, from the innermost to the outermost baiile, prevent reactants from flowing directly from one tray to the next and require the same to pass upwardly and into the space above the trays before flowing to the next one. Imperforate wall members 3.8, ill and 4!; which extend upwardly from the inner walls of the trays (except the outermost tray) to the top of the reactor and which are provided with expansion joints illustrated as 52, serve to define separate passageways above the trays for the flow of reactants from one tray to the next. Within each of these flow passageways, there are provideda plurality of spray nozzles 43, connected to inlet lines 44, for the introduction of liquid reactants into the vapor stream in the form of a:

fine spray.

The trays are filled with a granular contact material, which preferably is a mixture of cat-.

alyst (for example, a silica-alumina type catalyst if the reaction to be conducted is the cracking of hydrocarbons) and a granular inert material of high heat absorbing capacity (for example, artificially fused oxide such as described in Houdry Patent No. 2,414,812); The proportion of cat alyst'to heat absorbing material may vary widely depending upon the particular materials used and the amount of heat that it is desired to store in: the contact mass during each cycle, but generally. will be within the range of 1 :5 to 3 :1.

'Itris distinctly preferable that the perforate walls of the trays be so designed with respect to the number and size of perforations that the pressure drop across each wall during regeneration will be within the range of 0.2 to 1.0 lb./sq. in. and preferably of the order of 0.5 lb./sq. in. This will insure good distribution of regenerating gas flowing through the contact mass and will minimize by-passing in case of shrinkage of the contact mass within the tray. Such shrinkage has been found to occur almost invariably upon prolonged operation, and consequently it is of great importance that the inner and outer walls of the trays be properly orificed to give the desired presbe inwardly rather than outwardly; but in order to provide for having about the same space velocities throughthe several trays, it will be ad i The hot vapors issuing from bed I! likewise are 4 vantageous to design the reactor for flow from the inner to the outer tray, as described above, in order that the tray having the lowest volumetric capacity will be the one of smallest diameter.

In operation, during the on-stream or endothermic reaction period, hydrocarbon reactants are introduced through inlet nozzle l3 into the central space 33 and flow horizontally through the first bed of contact material into the annular space adjacent the bed. In passing through bed 15 the reactants will absorb heat from the contact material in excess of that necessary for the endothermic conversion reaction and accord ingly the vapor issuing from bed [5 will be at a higher temperature than the reactants entering the bed. The temperature will also be higher at this point than desired for reaction in the next catalytic bed Hi. This excess heat is utilized to vaporize the liquid reactants injected between the beds. Thus, the hot vapor from bed [5 fiows upwardly along baffle 36 and into the zone in the upper part of the reactor, where it commingles withliquid spray introduced through nozzles 43. vaporization of the liquid occurs and suflicient heat is thereby absorbed ,to reduce the temperature of the resulting vapor mixture to the desired value. The mixture then flows to and through bed It where heat is again picked up in excess of that necessary for maintaining the catalytic conversion reaction in the next bed. After pass- 1 ing through bed E6 the vapors commingle with the next liquid spray introduced through the spray nozzles positioned in the zone above thebed and the temperature is again reduced to the desiredyalue before the mixture fiows tobed [1.

mixed with sufficient liquid hydrocarbons int-ro-. duced through the next set of spray nozzles to regulate the temperature of the mixture passing to bed It to the desired level. Hot reaction prodl ucts issuing from the outermost bed pass from hydrocarbons the reactants flowing to bed 15 may --have a temperature of say 8OD-900 E; whereas the hydrocarbons issuing from bed l5 into the annular space adjacent thereto may have a temperature of 1000-4100" F, Sufiicient liquid reactants, at a temperature of say 200-600" F.,-may

be introduced as quenching material through the spray nozzles to cause the resulting vapor mixture passing to bed M5 to have a temperature of 800-900 F. 'Upon passing through bed 16, the' mixture will absorb suflicient heat to reach a temperature again of 1000-1lOO F. Similar fluctuations in temperature will occur as the reactants pass through the reactor and alternately come in contact with the spray streams and the other catalytic contact masses.

After the catalyst has become sufficiently inactivated due to deposition of carbonaceous material in the contact mass, the on-stream operation is stopped and the reactor is then purged with an inert gas (e. g. steam) or evacuated to removeoil vapors, The catalyst is then regenerated by blowing an oxygen-containing gas such as air through the beds to burn off th carbonaceous material. This may be done by passing the regenerating gas through the beds in series or by flowing separate streams of regenerating gas through the beds by means of suitable inlet and outlet connections (not shown). During the regeneration, heat is stored in the masses of contact material for utilization during the subsequent on-stream operation-as heat of reaction and as heat for vaporizing the hydrocarbon liquids injected between beds. l

Figure 3 shows a modified form of reactor in which the spray means for introducing the liquid reactants betweenbeds are positioned outside of the reactor. The reactor is illustrated as containingfollrbeds of catalytic contact material, shown as |5--d, l6a, ll--a and lB-a; but in this case the beds are of varying height, decreasing from the innermost to the outermost bed, inorder to permit better utilization of the space in the upper part of the reactor. The trays otherwise may be of essentially the same construction as described in connection with Figures 1 and 2. In the present modification, bafiles 36--a, 31--a and 38a positioned between the trays extend upwardly to the top of the reactor and imperforate wall members 39a,, 50 and 5| also extend from the top of the three innermost trays to the top of the reactor. Suitable expansion joints should, ofcoursebe included to provide for expansion or contraction of these elements. This arrangement, together with an external passageway leading around each baflle,,

serves to direct the fiow ofvapors outside of the reactor in passing from one bed to the next.

Each of th external vapor passageways comprises a flanged outlet conduit 52 connecting with a spray chamber 53 and thence with a tangential separator 54. A spray nozzle 55 is positioned within, the spray chamber for introduction of liquid reactants into the vapor stream in the form of a fine spray, Tangential separator 54 is provided with a bottom outlet line 56 for withdrawingany liquid which does not vaporize underthe prevailing temperature and 1 pressure conditions and with a vapor line 51 leading back to the reactor for introduction of the reaction mixture to the next catalyst bed. Advantageous features of this modification include the elimination of any contact between hot metal within the reactor and l the relativel cold liquid spray, as well as the prevention of any spray material which fails to vaporize from passing to the next catalyst bed.

It will be, understood thatthe drawings are merely illustrative of certain embodiments and that numerous specific :modifications may be made without departing fromthe scope of the invention. For example, it is apparent that reactants could be introduced into the central space within thereactor from the bottom rather than the top and, that the reactioniproducts could be withdrawn from the top outlet. It is also'evident that the reaction traysacould be constructed as alternate endothermic and exothermic reactions which comprises a vertically cylindrical outer shell, a plurality of annular-shaped trays positioned concentrically within said shell in radiallyspaced apart relation to each otherso as to provide an annular space between each two adjacent trays, each of said trays being adapted to retain therein a bed of granular contactjmaterial and comprising aninner perforate wall, an

outer perforate wall, an imperforate'top member and an imperforatebottom member, the outer most tray having an outer perforate wall of lesser diameter than said shell to provide; an annular extending across each annular space "between trays at one end thereof, a partitioning member space therebetween, an imperforate endmember extending from the other end of each tray to said shell, said partitioning members forming boundaries of passageways adjacent said other said imperforate end member at leastthroughout the length of the annular space to'pre vent short-distance flow from bed to bed, spray nozzles positioned in said passageways for introduction of liquid reactants into the flowing stream in the form ofa fine spray, fiuid flow means communicating from without said shell tothe space within the innermosttray and other fluid flow means communicating from without said shell to the outermost annular space.

2. Catalytic reaction apparatus for conducting alternate endothermic and exothermic reactions which comprises a vertically cylindrical outer shell, a plurality of annular-shaped trays posi-f tioned concentrically within said shell in radially spaced apart relation to each other so as toprovide an annular space between each two adjacent trays and a central space within the innerrnosttray, each of said trays being adapted to retain therein a bed of granular contact material andcomprising an inner perforate wall, an outer perforate wall and animperforate top member, a

circular imperforate bottom membereizteriding across the bottom of said central spaceand radially outward to the outer wall of the outermost tray, said outermost tray having an outer perforate wall of lesser diameter than said shell to provide an annular space therebetween, a cylindrical baffle positioned in each annular space between beds and extending vertically from said imperforate circular bottom member at least'to the upper end of the annular space so as to prevent short-distance fiowfrombed to bed,a partitioning member extending from the upper end of each tray to said shell, said partitioning members forming boundaries of passageways above the trays for flowing reactants from bed to bed,

spray means including a plurality of spray nozstream in the form of a fine spray, means forintroducing reactants into said central space and means for withdrawing reaction products from the outermost annular space.

3. Reaction apparatus which comprises acylindrical outer shell, a plurality of annular shaped trays positioned concentrically within said shellin radially; spaced apart relation and adapted eachto retain a bed of contact material, the inner and outer walls of each tray being perforated to receive and discharge reaction fluidsgchanmembers closing the annular spaces between trays at one end thereof; cylindrical bafil'es ex:

tending from said members at least throughout the length of each annular space to prevent shortdistance flow from bed to bed, partitioningmem bers extending fromthe other-end ofsaid trays to said tshel1,::'said :partitioning :members forming boundaries of passageways adjacent said other endiof' the .trayszior flowing. reaction fluids from bed =to ibed,:and=.spray-'means positioned in said passageways for introduction of :liquid reactant imtherlform of a fine: spray.

sReaction -app'aratus which comprises acylindricalzouter shell, a;-plurality of annular shaped trays ipositioned rconcentrically within said shell insradially spaced apart relation and adapted each ltowretainzzabed of contact material, the inner=-and outer :wallstof each tray being perforated to rreceive and discharge reaction Tfillids, ChEJIlIlElSifOl inflow and outflow of such fluids, thex-perforationsin the inner walliof the innern1ost-:.tray communicating with one channel and thej-perforationsin theouter'wall of the outermost tray communicating with the other channelsmem-b'ers: closing the annular spaces between trayscat one end thereof, cylindrical bafiles extending :fnomsaid, members at least throughout the :length of :each annular space but terminating short'of said shell tolprevent short-distance fiowi-from \bed to -bed,1 partitioning members extending from-the .otherendcof said trays to said shell,-said,partitioning members forming boundariescof -,passageways adjacentsaid other end of thertrays.-forxflowing reaction fiuidsifrom bed to bath-and spraymeansgpositioned in said passageways tor introduction. of liquid reactant in the formlotafinerspray.

.5. @Reactionapparatuswhich comprises a cylindrical outer shell, aagplurality of annular shaped trays positioned concentrically within said shell in radiallyspaced .1apart relation and adapted eacl'rztolretainabed ofcontact material, the inner and outer walls ofl-each-tray being perforated to receive and discharge-reaction fluids, channels fOl'ili'lflOW and outflow of such fluidathe perforationsin the-:inner wall of :thei-nnermost tray communicating withone channel and the perforationsi-nltheouter wall .of the outermost tray communicatingwiththeother channel, members closing-the.annularrspaces between trays at one end thereof, t cylindrical bafllesextending from said-members throughoutthe length of each annularspace sand to said shell .to prevent shortdistance.'flow:from bed torbed, partitioning memberse-xtendingfrom theother end of said trays torsaid shell, said partitioning members forming with that :portion 'of each adjacent cylindrical baflle which eX-tendsbeyond the annular space apassageway-for flowing reaction fluids .from bed to-beda conduit means outside ofsaid shell connecting each two adjacent passageways, and spray means positionedin saidpassageways for introduction of liquid reactant in the form of a fine-spray.

=.6.='Apparatusaccording.to claim 5 wherein said conduitrmeans includes a vapor-liquid separator ateatlocus-downstream from said spray means, said -separa-tor having means for withdrawing separatedsliquid,

7. ..Apparatus.'according to claim 6 wherein said vapor-liquid separator is -'a tangential type separe-tor.

Gatalyticmeaction apparatus for conducting alternate tendothermic and exothermic reactions which comprises ta vertically cylindrical outer shell, aplurality of annular-shaped trays positioned.JconcentricaII-ywithin said shell in radially sp-aced'apart relation to-each other soas to provide-an annularspace between each-two adjacent trays,eachtoffsaidtrays being adapted to retain therein-abed or, granularwcon-tact material and 1' comprising an :inner ;;pertorate wall; ;an outer perforate wall, an imperforate topmember-eand an jimperforate bottom member, .the outermost tray having an outer perforate wall: of lesser diameter than said "shell toprovide an. annular spacetherehetween, animperforate end member extending across 'each annular space between traysatonerend thereof, a' partitioning member extending '.-from the .otherend of each tray to said shell, saidpartitioning members forming with each adjacent partitioning member. a passageway :for flowing reactants from bed to bed,

a cylindrical bafile ineach-annular space betweenbedsextending vertically .from said ,imperforate end member ,at least throughout the length of the annular spacebut I terminating shortof said shell to prevent short-distance flow from bed-to bed, spray-.meanspositioned in each of said passagewaysior introduction of liquidlreactants into the flowing stream .inthe form. of aflne spray, fluidiflow means communicating from without said shelltothesspace lwithinthe innermost tray;

and other fiuid'flow means communicating from without saidshell to theoutermostannular space. 9. Catalytic reaction apparatus for conducting alternate endothermicand exothermic reactions which comprises a vertically cylindrical outer, shell, .a plurality .of annular-shapedtrays positioned concentrically Within said shell in radially spaced apart relationfto each other so as to ,provide an annular space between each two adja-' cent trays, each of tsaidtrays being .adapte'dtov retain therein abed of granular contact material and-comprising an inner "perforate walhanv outer perforate wall, an'lmper'forate 'top member f andan imperforatebottom member, the outermost tray havingan'outer perforate wallof lesser diameter than said shell to provide an annular space there'between, an imperforate end member extending across "each annular space between jacent :cylin'drical battle which extends beyond the annular space a flow passageway, conduit means'outside of said shell connecting each two adjacent flow passageways, spray means positioned in each of said conduit means for introduction ofrliquidrea'ctantsrinto' the flowing stream inthe formi'of arflne'spray,"fiuid flow'means communicatingirom without said shell to the space within: the :innermost tray and other fluid :flow means communicatingt'from without saidshell to theoutermost annular space.

10.. Apparatusraccording to claim "9 wherein said: conduit means includes a vapor-liquid separator at a locus downstream .from said 'spray means, said separator having means for withdrawing separated :liquid.

11. Apparatus according to claim 10 wherein said "vapor-liquid separator isza tangential type separator.

12. Catalytic reaction apparatus for "conducting alternate endothermicandzexothermic reactions which comprises avertica'llycylindrical outer shell, --a plurality of annular-shaped trays positioned concentrically within said shell in radially spaced apart relation to each other so as to provide an :annular space between each two adjacent. trays and acentral-ospace within the innermost tray, each of said trays being adapted to retain therein a bed of granular contact material and comprising an inner perforate wall, an outer perforate wall and an imperforate top member, a, circular imperforate bottom member extending across the bottom of said central space and radially outward to the outer wall of the outermost tray, said outermost tray having an outer perforate wall of lesser diameter than said shell to provide an annular space therebetween, a cylindrical baffle positioned in each annular space between beds and extending vertically from said imperforate circular bottom member to above the upper end of the annular space but terminating short of said shell to prevent short-distance flow from bed to bed, a partitioning member extending from the upper end of each tray to said shell, said partitioning member forming with each adjacent partititoning member a flow passageway around each baiile at its upper end, spray means including a plurality of spray nozzles positioned in each of said passageways for introduction of liquid reactants into the flowing stream in the form of a fine spray, means for introducing reactants into said central space and means for withdrawing reaction products from the outermost annular space.

13. Catalytic reaction apparatus for conducting alternate endothermic and exothermic reactions which comprises a vertically cylindrical outer shell, a plurality of annular shaped trays positioned concentrically within said shell in radially spaced apart relation to each other so as to provide an annular space between each two adjacent trays and a central space within the innermost tray, each of said trays being adapted to retain therein a bed of granular contact material and comprising an inner perforate wall, an outer perforate wall and an imperforate top member, a circular imperforate bottom member extending across the bottom of said central space and radially outward to the outer wall of the outermost tray, said outermost tray having an outer perforate wall of lesser diameter than said shell to provide an annular space therebetween, a cylindrical baiiie positioned in each annular space between beds and extending vertically from said imperforate circular bottom member throughout the length of the annular space and to said shell to prevent short-distance flow from bed to bed, a partitioning member extend ing from the upper end of each tray to said shell, said partitioning members forming with that portion of each adjacent cylindrical baiiie which extends above the annular space a flow passageway, conduit means outside of said shell connecting each two adjacent flow passageways, spray means including a plurality of spray nozzles positioned in each of said conduit means for introduction of liquid reactants into the flowing stream in the form of a fine spray, means for introducing reactants into said central space and means for withdrawing reaction products from the outermost annular space.

14. Apparatus according to claim 13 wherein said conduit means includes a vapor-liquid sen-- arator at a locus down-stream from said spray means, said separator having means for withdrawing separated liquid.

15. Apparatus according to claim 14 wherein said vapor-liquid separator is a tangential type separator.

16. Reaction apparatus which comprises a cylindrical outer shell, a plurality of annular shaped trays positioned concentrically Within said shell in radially spaced apart relation and adapted each to. retain a bed of contact material, the end walls of all said trays being closed and corresponding end walls of the trays being spaced from the adjacent end wall of the shell, the inner and outer walls of each tray being perforated to receive and discharge reaction fluids, channels for inflow and outflow of such fluids, the perforations in the inner wall of the innermost tray communicating with one channel and the perforations in the outer Wall of the outermost tray communicating with the other channel, partitioning members extending from the last-named end walls of the several trays toward the adjacent end wall of the shell and forming between them spaces for flow of reactant from bed to bed and preventing direct fluid flow between said spaces, cylindrical bafiies extending between, and at least throughout the length of, said trays to prevent short distance fluid flow from bed to bed but allowing fluid flow from bed to bed at loci beyond the end walls of the trays that are spaced from the adjacent end wall of the shell as hereinbefore specified, and spray means communicating with the spaces between partitions for introduction of liquid reactant in the form of a fine spray into reactant flowing from bed to bed.

LELAND W. T. CUMMINGS.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 1,970,923 Spalding Aug. 21, 1934 2,450,804 Loy Oct. 5, 1948 

1. CATALYTIC REACTION APPARATUS FOR CONDUTING ALTERNATE ENDOTHERMIC AND EXOTHERMIC REACTIONS WHICH COMPRISES A VERTICALLY CYLINDRICAL OUTER SHELL, A PLURALITY OF ANNULAR-SHAPED TRAYS POSITIONED CONCENTRICALLY WITHIN SAID SHELL IN RADIALLY SPACED APART RELATION TO EACH OTHER SO AS TO PROVIDE AN ANNULAR SPACE BETWEEN EACH TO ADJACENT TRAYS, EACH OF SIAD TRAYS BEING ADAPTED TO RETAIN THEREIN A BED OF GRANUALR CONTACT MATERIAL AND OCMPRISING AN INNER PERFORATE WALL, AN OUTER PERFORATE WALL, AN IMPEFORATE TOP MEMBER AND AN IMPERFORATE BOTTOM MEMBER, THE OUTERMOST TRAY HAVING AN OUTER PERFORATE WALL OF LESSER DIAMETER THAN SAID SHELL TO PROVIDE AN ANNULAR SPACE THEREBETWEEN AN IMPERFORATE END MEMBER EXTENDING ACROSS EACH ANNULAR SPACE BETWEEN TRAYS AT ONE END THEREOF, A PARTITIONING MEMBER 